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WO2004055840A1 - Bobine d'induction et bobine d'induction composite - Google Patents

Bobine d'induction et bobine d'induction composite Download PDF

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Publication number
WO2004055840A1
WO2004055840A1 PCT/JP2003/015930 JP0315930W WO2004055840A1 WO 2004055840 A1 WO2004055840 A1 WO 2004055840A1 JP 0315930 W JP0315930 W JP 0315930W WO 2004055840 A1 WO2004055840 A1 WO 2004055840A1
Authority
WO
WIPO (PCT)
Prior art keywords
coil unit
core
unit according
electric wires
insulator
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Ceased
Application number
PCT/JP2003/015930
Other languages
English (en)
Japanese (ja)
Inventor
Ichiro Tatsusawa
Takaaki Cyuzawa
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Panasonic Electric Works Co Ltd
Original Assignee
Matsushita Electric Works Ltd
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Priority claimed from JP2002362829A external-priority patent/JP2004193506A/ja
Priority claimed from JP2002365491A external-priority patent/JP2004200309A/ja
Application filed by Matsushita Electric Works Ltd filed Critical Matsushita Electric Works Ltd
Priority to AU2003289050A priority Critical patent/AU2003289050A1/en
Publication of WO2004055840A1 publication Critical patent/WO2004055840A1/fr
Anticipated expiration legal-status Critical
Ceased legal-status Critical Current

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Classifications

    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F27/00—Details of transformers or inductances, in general
    • H01F27/28—Coils; Windings; Conductive connections
    • H01F27/2847—Sheets; Strips
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F27/00—Details of transformers or inductances, in general
    • H01F27/28—Coils; Windings; Conductive connections
    • H01F27/32—Insulating of coils, windings, or parts thereof
    • H01F27/324—Insulation between coil and core, between different winding sections, around the coil; Other insulation structures
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F37/00—Fixed inductances not covered by group H01F17/00

Definitions

  • the present invention relates to a coil unit and a composite coil unit.
  • Figures 57 and 58 show conventional toroidal choke coils.
  • the toroidal choke coil refers to a core 100 or 101 having a closed magnetic path and a winding 102 wound around the core.
  • the core shape may be a cylindrical shape, a letter or a rectangular parallelepiped shape, and the hole may be a round hole or a square hole.
  • the pore radius a of the toroidal core can be obtained by the following equation (1) from the NI value in consideration of the saturation caused by the current I and the number of turns N.
  • B magnetic flux density, ⁇ : magnetic permeability
  • ⁇ I ( ⁇ ⁇ 27 ⁇ ⁇ a) / ⁇ ⁇ ⁇ ⁇ (1)
  • DC-DC converters use a high-voltage battery used for in-vehicle applications such as electric vehicles and hybrid power sources to transform the high voltage of the high-voltage battery into a low voltage to charge the low-voltage battery and supply power to the load It does.
  • large-capacity switching transformers with output capacities of several hundred W to several kW have been provided.
  • a large core is used to cope with a large current, and the winding is made of a thick stranded wire or a flat wire.
  • the electric power capacity was increased by forming.
  • Patent Document 1 Japanese Patent Application Laid-Open No. 1-27204 (hereinafter referred to as Patent Document 1).
  • Patent Document 1 Japanese Patent Application Laid-Open No. 1-27204
  • This conventional technique has the advantage that a rectangular wire can be wound around a seamless (uncut) core without deformation.
  • a seamless core is a state in which a winding is inserted in a divided state, and a core that has a seam formed by connecting divided pieces thereafter has no seam and is not split.
  • Seamless cores have the advantage of significantly reducing the man-hours required to manufacture the cores themselves, as well as having no problem of deterioration in the magnetic properties of the cores themselves and further reducing core loss and copper loss. . Seamless cores also have the advantage of not causing the noise problems associated with seam vibration.
  • this conventional technology requires that an insulating layer having a width larger than the width of the conductor plate be inserted between the windings in order to satisfy the insulation standard between the conductors. It is necessary to use a material with a sufficient thickness to prevent breakage due to the end of the rectangular conductor plate, and to use an insulating layer to secure between the conductor plate and the insulating layer. However, it is necessary to use a high-strength coil, which causes a decrease in the space factor of the winding, resulting in an increase in coil size and an increase in copper loss due to an increase in leakage inductance. Was.
  • Patent Document 2 Japanese Patent Application Laid-Open Publication No. 2002-237374 discloses that an insulating tape is provided in advance as shown in FIG.
  • a method of forming a coil by stacking layers one by one while inserting into a core is disclosed. Each time the conductive plates 350 are stacked, one end thereof is connected to one end of the connecting conductive plate 352. The other end of the conductor plate 352 is connected to the other end of the conductor plate 350 to be laminated next. By repeating this process, a coil is formed.
  • This conventional technology has the advantage of being able to be wound around a seamless core without deforming a rectangular wire, and the fact that each conductor plate 350 is insulated in advance by an insulating tape 351 allows the coil to be wound. It has the advantage of realizing miniaturization and low loss.
  • the present invention has been made in view of the above circumstances, and an object of the present invention is to provide a coil unit and a composite coil unit which can simplify a manufacturing process, reduce a manufacturing cost, and are highly resistant to vibration. It is in.
  • the coil unit of the present invention embeds and holds the plurality of electric wires so that the plurality of electric wires keep an interval from each other and at least the first and second ends of each of the plurality of electric wires are exposed. It has a structure in which an insulator is inserted into a through hole of a magnetic core.
  • FIG. 1 is a perspective view showing a wiring portion of a coil unit according to Embodiment 1 of the present invention.
  • FIG. 2 is a perspective view showing the single flat wire of FIG.
  • FIG. 3 is a diagram illustrating a state in which the holding unit is inserted into the toroidal core in the coil unit of FIG.
  • FIG. 4 is a perspective view illustrating the connecting plate of FIG.
  • FIG. 5 shows the coil unit of Fig. 1 with a single rectangular wire connected to a connecting plate.
  • FIG. 4 is a perspective view showing the inside of the wiring section of FIG.
  • FIG. 6 is a perspective view showing a configuration example of a coil unit according to Embodiment 2 of the present invention.
  • FIG. 7 is a perspective view showing another configuration example of the coil unit according to Embodiment 2 of the present invention.
  • FIG. 8 is a perspective view showing still another configuration example of the coil unit according to Embodiment 2 of the present invention.
  • FIG. 9 is a perspective view schematically showing an example of the coil unit according to Embodiment 2 of the present invention.
  • FIG. 10 is a diagram showing a conventional toroidal choke coil compared with the coil unit of FIG.
  • FIG. 11 is an explanatory diagram showing the specifications of the choke coil of FIG. 10 in a table format.
  • FIG. 12 is an explanatory diagram showing the specifications of the choke coil in FIG. 9 in a table format.
  • FIG. 13 is a graph showing the relationship between core thickness and volume for the coils of FIGS. 9 and 10.
  • FIG. 14 is a perspective view schematically showing another example of the coil unit according to Embodiment 2 of the present invention.
  • FIG. 15 is a perspective view showing a conventional square-hole toroidal choke coil.
  • FIG. 16 is a perspective view showing a wiring portion of the coil unit according to Embodiment 3 of the present invention.
  • FIG. 17 is a perspective view showing the inside of the wiring section of FIG.
  • FIG. 18 is a perspective view showing a state in which a coil unit having a two-turn winding is configured using the wiring section of FIG.
  • FIG. 19 is a perspective view showing the inside of the coil unit of FIG.
  • FIG. 20 is a perspective view showing a state in which a coil unit having a three-turn winding is formed using the wiring section of FIG.
  • FIG. 21 is a perspective view showing the inside of the coil unit of FIG.
  • FIG. 22 is a perspective view showing a wiring section according to Embodiment 4 of the present invention.
  • FIG. 23 is a perspective view showing a state where the wiring section of FIG. 22 is inserted into a toroidal core.
  • FIG. 24 is a perspective view showing a coil unit according to Embodiment 5 of the present invention.
  • FIG. 25 is a schematic configuration diagram showing a coil unit according to Embodiment 6 of the present invention.
  • FIG. 26 is a schematic configuration diagram showing a wiring portion of the coil unit of FIG.
  • FIG. 27 is an explanatory diagram showing the arrangement of electric wires in the wiring section of FIG.
  • FIG. 28 is a perspective view showing an example of the shape of the core of the coil unit of FIG. 25.
  • FIG. 29 is an explanatory diagram showing how to attach the core in the coil unit of FIG. 25.
  • FIG. 30 is a schematic configuration diagram showing another example of the arrangement of the cores in the coil unit of FIG.
  • FIG. 31 is a perspective view showing another example of the shape of the core in the coil unit of FIG. 25.
  • FIG. 32 is a schematic configuration diagram showing another example of the coil unit according to Embodiment 6 of the present invention.
  • FIG. 33 is a schematic configuration diagram showing how to attach a core in the coil unit of FIG.
  • FIG. 34 is a perspective view showing a main part of still another example of the coil unit according to Embodiment 6 of the present invention, with a part thereof broken away.
  • FIG. 35 is an explanatory view showing still another example of the coil unit according to Embodiment 6 of the present invention.
  • FIG. 36 is an explanatory diagram illustrating a configuration example of a winding in the coil unit according to Embodiment 7 of the present invention.
  • FIG. 37 is an explanatory diagram showing another configuration example of the winding in the coil unit according to Embodiment 7 of the present invention.
  • FIG. 38 is a schematic configuration diagram of a coil unit having the windings of FIG.
  • FIG. 39 is a schematic configuration diagram showing another example of the coil unit according to Embodiment 7 of the present invention.
  • FIG. 40 is an explanatory diagram showing the arrangement of electric wires according to the eighth embodiment of the present invention.
  • FIG. 41 is an explanatory diagram illustrating an example of the arrangement of the electric wires and the connection portions in FIG. 40.
  • FIG. 42 is a circuit diagram illustrating a conversion using another example of the coil unit according to the eighth embodiment of the present invention.
  • FIG. 43 is an explanatory view showing the coil unit of FIG.
  • FIG. 44 is a perspective view showing a coil unit according to Embodiment 9 of the present invention.
  • FIG. 45 is an exploded perspective view of the coil unit of FIG.
  • FIG. 46 is a perspective view showing the coil unit according to the tenth embodiment.
  • FIG. 47 is a perspective view showing a coil unit according to Embodiment 11.
  • FIG. 47 is a perspective view showing a coil unit according to Embodiment 11.
  • FIG. 48 is a manufacturing process diagram of the coil unit according to Embodiment 12.
  • FIG. 49 is a manufacturing process diagram of the coil unit according to Embodiment 12.
  • FIG. 50 is a diagram showing the manufacturing process of the coil unit according to Embodiment 12.
  • FIG. 51 is a manufacturing process diagram of the coil unit according to Embodiment 12.
  • FIG. 52 is a perspective view of the coil unit according to Embodiment 12.
  • FIG. 52 is a perspective view of the coil unit according to Embodiment 12.
  • FIG. 53 is a drawing illustrating the manufacturing process of the coil unit according to the thirteenth embodiment.
  • FIG. 54 is a manufacturing process diagram of the coil unit according to Embodiment 13.
  • FIG. 55 is a drawing showing the manufacturing process of the coil unit according to Embodiment 13.
  • FIG. 56 is a perspective view of the coil unit according to Embodiment 13.
  • FIG. 57 shows a conventional toroidal choke coil.
  • FIG. 58 is a diagram showing another example of the conventional toroidal choke coil.
  • FIG. 59 is a perspective view showing a single-layer winding of a conventional coil.
  • FIG. 1 is a perspective view showing a wiring portion that is a main portion of the coil unit according to the first embodiment.
  • the wiring portion 31 according to the present embodiment includes a holding portion 3 which is a resin insulator formed in a substantially U shape (in other words, a substantially U shape), and a flat rectangular wire 2 a which is an electric wire. , 2b, and an output rectangular single wire 5 which is also an electric wire.
  • the rectangular single wires 2a and 2b are conductor plates, and are bent into a substantially U shape in plan view along the holding portion 3 and embedded in the holding portion 3 with both ends protruding outward. .
  • the output rectangular single wire 5 is a conductor plate extending linearly, and has one end protruding from the tip of one leg 3 a of the holding portion 3 and the other end as shown in FIGS. 1 and 2.
  • the holder 3 is embedded in the holder 3 so as to protrude from the central piece 3 c to the outside.
  • the rectangular single wires 2a and 2b as the conductor plates and the rectangular single wire for output 5 are held by being embedded in the holding section 3 in a state where they are stacked at predetermined intervals.
  • the wiring section 31 connects the rectangular single wires 2a and 2b and the output rectangular single wire 5 between each other. It can be easily formed by integrally molding the insulating material of the holding portion 3 so as to embed these single wires 5, 2a, and 2b while supporting them with a jig (not shown) so as to keep the gap. .
  • the shape of the leg 3a of the holding part 3 is substantially the same as the shape of the through hole 1a of the toroidal core 1 which is a core of a magnetic material made of ferrite, for example.
  • the distance between one leg piece 3a and the other leg piece 3b is substantially equal to the distance between the outer peripheral surface and the inner peripheral surface of the toroidal core 1.
  • the toroidal core 1 is inserted into the through hole 1a and the other leg 3b.
  • the toroidal core 1 used in the present embodiment is a core having a rectangular parallelepiped shape and having square holes.
  • the shape of the core 1 of the coil unit of the present invention is not limited to the present embodiment.
  • a substantially S-shaped connecting plate 6a as a connecting member is arranged so that the opening side of the holding portion 3 is closed.
  • One end of the winding is formed by connecting the end of the single rectangular wire 2a protruding from the tip of the other leg 3b of the holding portion 3 to one end of the connecting plate 6a.
  • the other end of the connecting plate 6a is connected to one end of a rectangular single wire 2b protruding from the tip of one leg 3a of the holding portion 3, and the other end of the rectangular single wire 2b is connected to another connecting plate. 6b is connected to one end, forming the next turn of the winding.
  • the other end of the connecting plate 6b is connected to one end of a rectangular output single wire 5 protruding from the tip of one leg 3a of the holding portion 3. In this way, the coil unit is completed as a choke coil unit.
  • the end to which the connecting plates 6a and 6b are not connected can be used as an end for connection to an external circuit (not shown).
  • FIG. 5 shows the inside of the wiring portion 31 to which the connecting plates 6a and 6b are connected.
  • the length of one leg is The length of the other leg is longer than the length of the other leg, and when comparing the two rectangular single lines 2a and 2b, the length of the shorter leg of the rectangular single line 2a and the length of the rectangular single line 2b are longer.
  • the length of the leg pieces is made equal to facilitate connection of the connecting plates 6a and 6b.
  • the connecting plates 6a and 6b can be attached to each other with a step. This also applies to the connection of the connecting plates 6a and 6b. Easy connection. Furthermore, since the main surfaces of the rectangular single wires 5, 2a and 2b are parallel to each other, the connecting plates 6a and 6b are connected to the fixed main surfaces of the rectangular single wires 5, 2a and 2b, that is, the example in FIG. Then, it may be connected to the upper main surface. This also facilitates connection of the connecting plates 6a and 6b.
  • the flat rectangular solid wires 5, 2a, and 2b which are the electric wires, are embedded and held in the holding unit 3, so that the holding unit constituting the wiring unit 31 is held.
  • a structure in which a plurality of electric wires penetrate the core 1 is completed.
  • a winding configuration can be easily realized. That is, it is not necessary to wind the rectangular winding, and unlike the conventional technology disclosed in Patent Document 2, it is also necessary to insert the rectangular single wires 5, 2a and 2b into the core 1 while laminating them one by one. Absent.
  • FIG. 6 or FIG. 7 In order to connect two toroidal choke coils according to the first embodiment in parallel, as shown in FIG. 6 or FIG. 7, one end of the side where the connecting plate 6 a of the rectangular single wire 2 a is not connected is connected to the input terminal.
  • the ends of the flat rectangular output wires 5 protruding from the central piece 3 c of the holding portion 3 may be connected to each other by the output terminal plate 8 while being connected by the plate 7.
  • the direction in which the winding thickness comes out can be arbitrarily selected as shown in FIG. 6 or FIG.
  • FIG. 8 it is possible to configure a unit by connecting a number of toroidal choke coils in parallel.
  • FIG. 9 schematically shows the choke coil unit A of the present embodiment.
  • This choke coil unit A is provided with two toroidal-type yoke coils A1 in which a rectangular winding 2 as a wiring portion is wound around a toroidal core 1 made of a core material such as ferrite.
  • One choke coil unit A is formed by connecting the toroidal choke coils A 1 and A 1 in parallel with each other.
  • the hole diameter X of the toroidal core 1 determined from the NI value can be smaller than that of the conventional undivided toroidal choke coil.
  • the inductance L required for each toroidal choke coil A1 is doubled.
  • the hole diameter X determined by the NI value can be small, the choke coil unit A can be made smaller than the conventional toroidal chiyoke coil even if the inductance L is doubled. .
  • the size of the conventional toroidal choke coil and the size of the yoke coil unit A of the present embodiment will be compared based on the volume occupied by the core, with numerical examples given below.
  • FIG. 10 shows an example of a conventional toroidal choke coil X using a rectangular winding 201 and has the specifications as shown in FIG.
  • the reason for determining this specification will be described.
  • the design conditions are such that the height (outer diameter y) of the toroidal core 200 is 200 [mm] or less (as low as possible) and the thickness z is 100 [mm] at the maximum.
  • N I (BX 2 ⁇ a) / n
  • the outer diameter y of the toroidal core 200 can be obtained from the thickness z [m] of the toroidal core 200 and the inductance L [H] using the following equation (3).
  • B core outer radius [m]
  • a hole radius [m]
  • L core L value [H]
  • z core thickness [m]
  • N Number of turns.
  • V200 X b 2 X z
  • V200 2184045. 8 [mm 3 ]
  • Fig. 1 shows the specifications of the choke coil unit A of this embodiment when the overall current value I, the inductance L, the number of evenings N, the core thickness z, and the core material are the same as the conventional one. See Figure 2.
  • Vl 593515. 5 [mm 3 ]
  • the current flowing per toroidal core is reduced, so that the hole diameter X of the toroidal core can be reduced, and Even considering the large L value required for each toroidal core, the size can be reduced compared to conventional toroidal choke coils.
  • Fig. 13 shows the conventional toroidal core when the thickness z of the toroidal core was changed.
  • the volume V200 of 200 and the volume V2 of two toroidal cores 1 of choke coil unit A are shown. According to this graph, in order to make the core outer diameter y as small as possible, the larger the thickness z of the core, the more the effect of miniaturization of the choke coil unit A of the present embodiment as compared with the conventional toroidal core 200. You can see that there is.
  • the cylindrical core 1 having a round hole is used.
  • the choke coil unit A ' may be configured by using this.
  • the L value of the coil is determined by the ratio of the inner diameter to the outer diameter, if the rectangular hole is used under the condition that the same rectangular winding 2 is used, the outer diameter will not be large because it will be larger than the round hole
  • the L value is not the same as the above, the size can be reduced even when the rectangular hole choke coil unit A 'is used as compared with the conventional rectangular hole toroidal type choke coil unit. That is, in the conventional toroidal choke coil X ′ shown in FIG. 15, since the diagonal line of the square hole determines the outer diameter, the size X of the square hole is 226.3 [mm] X 226.
  • the core volume V200 ' is
  • FIG. 16 shows the holding section 3 of the present embodiment.
  • the holding part 3 has an extension piece 3 d extending from the tip of one leg 3 a of the holding part 3 of the first embodiment so as to face one end of the rectangular single wire 2 a.
  • An extension 3e is formed at the tip of d.
  • an input switching piece 9 to which a current is input at one end and the other end is connected to the single rectangular wire 2a or 2b as described later is embedded with both ends exposed to the outside. .
  • the input switching piece 9 has an end on the side connected to the single rectangular wire 2a or 2b, which is divided into two forks 9a and 9b and exposed to the outside. Further, the holding unit 3 holds the rectangular single wires 2a and 2b and the output rectangular single wire 5 in a stacked state at predetermined intervals, as in the second embodiment.
  • the portion 9a on the side closer to the extension piece 3d and one end of the conductor piece 2a are Connect the other end of the conductor piece 2a and one end of the conductor piece 2b with a connecting plate 6a, and connect the other end of the conductor piece 2b and one end of When connected by the connecting plate 6b, a three-turn winding can be formed.
  • the number of turns can be changed by the holding unit 3 holding the plurality of flat rectangular single wires 2a and 2b and connecting the connecting plates 6a and 6b by selecting the flat rectangular single wires 2a and 2b.
  • a choke coil having a plurality of inductances L can be realized with one holding unit 3.
  • the present embodiment is different from the first embodiment in that the holding portion 3 inserted into the through hole 1a of the toroidal core is provided on one leg 3a of the holding portion 3 as shown in FIG. It is characterized in that a locking claw 3f is provided as a retaining part for preventing the core from coming off, that is, a fixing means for fixing the holding part 3 to the toroidal core 1.
  • the locking claw 3 has two slopes on the outer surface at the tip of one leg piece 3a, which are parallel to the single rectangular wires 2a, 2b, and an inclined surface that slopes outward as it approaches the center piece 3c of the holding portion 3. It is formed so that it may have. Further, the distance from the rear surface 3 g of the locking claw 3 f to the central piece 3 c of the holding portion 3 is formed to be substantially the same as the thickness of the toroidal core 1.
  • one leg piece 3a is inserted into the through hole 1a of the toroidal core 1 while elastically deforming the locking claw 3f inside the holding portion 3. 2
  • the back surface 3 g of the locking claw 3 f engages with the peripheral edge 1 b of the toroidal core 1 and the toroidal core 1 engages the back surface of the locking claw 3 f 3 It is fixed to the toroidal core 1 by being sandwiched between g and the central piece 3 c of the holding portion 3.
  • the fixing strength between the toroidal core 1 and the holding section 3 after being inserted into the toroidal core 1 is increased, and for example, the seismic resistance, which is important when the Chiyo coil unit is mounted on a vehicle, is improved. Can be.
  • This embodiment is different from the first embodiment in that the toroidal core 1 is divided into two (toroidal cores 1A and 1B) as shown in FIG. 24, and the holding portion 3 is made of a flexible resin. It is characterized in that the rectangular single wires 2a, 2b and the output rectangular single wire 5 are formed of a conductive material having flexibility. The rectangular single wires 2a and 2b and the output rectangular single wire 5 can have flexibility by, for example, setting the thickness to a certain value or less.
  • the holding portion 3 can be freely bent even after assembly, and the degree of freedom of the shape can be increased. Therefore, it is possible to cope with a change in the terminal position and the like to some extent.
  • the coil unit according to the present embodiment holds a plurality of (two in FIG. 25) electric wires 21 side by side so that the directions of both ends are aligned, and holds each electric wire 21. And a core 24 made of a magnetic material and having a through-hole 24 a through which the wiring portion 23 passes. Terminals 21a exposed from the insulator 22 are provided at both ends of each wire 21. It is.
  • the wiring portion 23 has a structure in which an insulator 22 made of synthetic resin embeds and holds two electric wires 21, and has a U-shape (U-shape) as shown in FIG. 26. Is formed. As shown in FIG. 27, inside the wiring portion 23, the electric wires 21 are respectively U-shaped, held apart from each other, and insulated from each other.
  • the wiring portion 23 supports the plurality of electric wires 21 with a jig (not shown) so as to keep a distance from each other, and uses an insulating material of an insulator 22 so as to embed these electric wires 21. It can be easily formed by integrally molding using the illustrated mold.
  • the core 24 is a general one in which a wiring portion, which is a through-hole, is formed in a magnetic material such as ferrite and a through-hole 24 a is formed in a cylindrical shape as shown in FIG. As shown by arrow B1 in FIG. 29, both ends of the wiring portion 23 are attached to the wiring portion 23 by passing through the wiring portion insertion holes 24a.
  • two cores 24 may be mounted side by side on one end of the wiring portion 23.
  • the core 24 may have a rectangular tube shape as shown in FIG.
  • the electric wire 21 is embedded and held in the insulator 22, the same effect as described in the first embodiment can be obtained. That is, there is no need to wind the electric wire 21, and unlike the prior art disclosed in Patent Document 2, there is no need to insert the electric wire 21 into the core 1 one by one. Since the manufacturing process is simplified, expensive equipment is not required and manufacturing costs can be reduced. In addition, since a general single wire can be used as the electric wire 21 instead of a rectangular wire, the cost can be further reduced by using a general single wire. Further, by appropriately selecting the number and size of the cores 24, the shape and the specifications of the core capacity can be easily changed.
  • a retaining portion 41 for retaining the core 24 may be protruded from the insulator 22 as shown in FIG.
  • the retaining portion 41 is provided at an end of the insulator 22 in a direction along the electric wire 21, for example.
  • the shape of the retaining portion 41 is, for example, that the inclined surface 41 a inclined in a direction away from the electric wire 21 toward the direction approaching the center of the wiring portion 23 along the electric wire 21 is formed from the electric wire 21.
  • the pull-out stopper 44 11 is formed as described above, it is arranged as shown by the arrow BB 22 in FIG. 33 33. Both ends of the wiring section 22 33 are pushed and pushed into the cocoa area 22 44's wiring section insertion hole 2244 aa. After the stopper portion 44 11 is radiused and passes through the wiring line portion of the cocoa hole 22 44 ⁇ ⁇ through-hole hole 22 44 aa, after that as shown in FIG. As shown in the figure, it returns to its home position and is hooked on Cocoa 2244. . If this configuration is adopted, the cocoa core 2244 can be prevented from falling off, and the vibration and vibration resistance can be improved. It is suitable and suitable for use in vehicle mounting. . Also, the cocoa stove should be lowered as compared with the case where a separate component can be installed to prevent the cocoa door 22 44 from being pulled out. The place where you can lower it is complete. .
  • the insulating insulator 22 22 and the electric wire 22 11 are connected as shown in FIG.
  • Each of them may be formed of a material having flexible flexibility. . If this configuration is adopted and adopted, it is necessary to match the wiring and wiring section 2233 to the installation site and to deform and deform it. Can be completed. .
  • the length in the direction along the power line 22 11 is used instead.
  • a cocoa core 22 44 with a small length and a small dimension is used in the direction along the power line 22 11 as shown in Fig. 33 55.
  • the wiring and wiring portion 2233 deform and deform more and more flexibly and flexibly.
  • the diameter of the electric power line 2211 can be suppressed to a certain degree or less, so that sufficient flexible bending can be achieved.
  • the winding wire is composed of 22 electric wires 22 11) and the connecting / connecting member 22 55. It is. .
  • the winding wire is formed as described above, a pair of winding windings of 22 turns is formed, and FIG. 33 88
  • the terminal portion 21 a to which the connection member 25 is not connected can be used as a terminal for connecting to an external circuit such as a circuit board (not shown).
  • the winding can be easily formed without using special equipment.
  • the plurality of wiring parts 23 are connected to one terminal part 21 a of each wiring part 23 to one terminal part 21 a of the other wiring part 23. If used together, more cores 24 can be added, so the core capacity can be increased over a wider range. You can choose.
  • the coil unit according to the present embodiment embeds and holds a plurality of (six in FIGS. 40 and 41) electric wires 21 with an insulator 22.
  • a U-shaped wiring portion 23 is formed, a core 24 is attached to the wiring portion 23, and one terminal portion 21a of the wiring portion 23 and the other terminal portion of the wiring portion 23 are formed.
  • 21a which is formed by adding a connecting member 25 for electrically connecting the ends of the wires 21 different from each other.
  • the number of windings of the winding can be freely set within a range that does not exceed the number of electric wires 21.
  • one of the electric wires 21 forms a primary winding of one turn, and three of the electric wires 21 and two connecting members 5 and a force, etc. Constructs a secondary winding of three turns.
  • the surplus terminal 21a may be cut off.
  • FIG. 42 is a circuit diagram showing an example of a DC-DC converter using the coil unit according to the present embodiment.
  • This DC-DC converter is a forward converter, and includes a DC power supply E, a switching transformer T having a primary winding connected between output terminals of the DC power supply E via a switching element SW, and a switching element SW. It includes a drive circuit P for controlling on / off and a smoothing circuit S for smoothing the output on the secondary side of the switching transformer T and supplying the output to the load W.
  • a technique for preventing magnetic saturation by a reset circuit R S in which a series circuit of a diode 26 and an auxiliary winding I is provided in parallel with a primary winding of a switching transistor T is known.
  • a diode 26 is previously connected in series to one of the electric wires 21, and a winding composed of the electric wire 21 and the connecting member 25 is provided.
  • the auxiliary winding I is formed on the force source side of the diode 26, and these can be connected in parallel to the primary winding.
  • the coil unit according to the present embodiment The two wiring portions 23 similar to the wiring portions 23 used in the above, and a core 24 having a plurality of (four in FIG. 44) wiring portions made of a magnetic material and having through holes 24 a formed therein. Is provided. Each end of each wiring portion 23 is passed through a wiring portion through hole 24a, which is one through hole.
  • the core 24 as described above includes a pair of halves 6 attached to the wiring part 23 from both sides in the direction in which the wiring parts 23 are arranged, as indicated by an arrow B3. Consist of one.
  • Each half body 61 has a plate-like shape in which a groove 61 a for accommodating a part of the wiring part 23 is provided on the bottom surface.
  • the cores 24 attached to the plurality of locations of the plurality of wiring portions 23 can be manufactured at once, instead of manufacturing them one by one. Also, unlike the case where a plurality of cores 24 each having one wiring portion and a through hole 24a are provided, the cores 24 do not collide with each other when subjected to vibration and are not damaged.
  • FIG. 46 is a perspective view showing the coil unit according to the tenth embodiment.
  • the electric wire 21 is a rectangular wire that is a substantially U-shaped conductor plate in plan view, similarly to the coil unit according to the first embodiment, and a plurality of electric wires 21 are stacked on the main surface thereof. It is embedded in a substantially U-shaped insulator 22 in a layered state. Further, the core 24 is inserted into both of the pair of legs of the substantially U-shaped insulator 22, and the core 24 is divided into a plurality in each leg. By dividing the core 24 along the electric wire 21 in this way, a common core is prepared for coil units of various specifications, and the inductance is different only by changing the number of cores to be used. It is possible to form coil units of various specifications.
  • FIG. 47 is a perspective view showing a coil unit according to Embodiment 11.
  • FIG. The basic configuration of this coil unit is the same as that of the coil unit according to the sixth embodiment.
  • the insulator 22 embeds only the legs of the plurality of substantially U-shaped electric wires 21. Even with such a configuration, it is possible to hold the plurality of electric wires 21 with sufficient strength. Further, an insulator 22 is fixed to the support plate 71, and Therefore, the strength is reinforced.
  • the connection member 25 is substantially S-shaped in a side view, and is connected to the upper main surface of the end of one electric wire 21 and the lower main surface of the end of another electric wire 21. ing. Accordingly, when connecting the connection member 25 to the electric wire 21 by welding or the like, interference by another electric wire 21 can be eliminated, and the efficiency of the work of attaching the connection member 25 is improved.
  • FIGS. 48 to 51 are process diagrams showing the steps of manufacturing the coil unit according to Embodiment 12, and FIG. 52 is a completed view thereof.
  • wires 21 A and 21 B shown in FIG. 48 are prepared.
  • Each of the electric wires 21A and 21B is a rectangular wire which is a substantially U-shaped conductor plate in side view.
  • a pair of ends of each of the electric wires 21A and 21B is provided with a plate-like terminal portion 72 which is bent and protrudes from the main surface so as to stand upright on the main surface.
  • the terminal portion 72 can be formed, for example, by bending.
  • the electric wires 21A and 21B are stacked at an interval from each other such that the electric wire 21A is on the outside and the electric wire 21B is on the inside.
  • the terminal portion 72 is provided for facilitating the connection between the end of the electric wire 21A and the end of the electric wire 21B with a flat connecting member 25.
  • the connection members 25 are attached not in the process of FIG. 49 but in a later process.However, in order to show the positional relationship of the four terminal portions 72, the connection after the connection is performed for convenience.
  • Member 25 is depicted in FIG.
  • a pair of terminal portions 72 to which the connecting member 25 is to be connected are arranged on the same plane.
  • the wiring portion 23 is completed by embedding the two electric wires 21 A and 21 B with the insulator 22.
  • the insulating material is integrally molded using a mold (not shown) This is easily achieved by: In the example of FIG. 50, the insulator 22 embeds the wires 21 A and 2 IB so that the connecting portion 75 of the pair of legs of the substantially U-shaped wire 21 is selectively exposed. .
  • the insulator 22 is inserted into the through hole 24 a of the wiring portion which is a through hole selectively formed in the core 24.
  • a pair of legs of the substantially U-shaped electric wires 21 A and 21 B penetrate the core 24.
  • the wiring portion 23 can be firmly grasped and easily inserted into the core 24 without damaging or deforming the insulator 22.
  • the exposed joint portion 75 is easily buried with the insulator 22 while holding the wires 21 A and 2 IB by holding the wires 21 A and 2 IB by a jig (not shown). be able to.
  • a coil unit is completed as a choke coil unit having one double-turned winding.
  • the conductor plates are used for the electric wires 21A and 21B, and they are laminated with an interval therebetween, so that a coil unit having a large current capacity is compactly realized.
  • the outline of the electric wires 21A and 21B in a side view is substantially U-shaped, similarly to the coil unit according to Embodiments 1 to 11, the direction of the end of the electric wire to which the connecting member 25 is to be connected.
  • the connection members 25 are easy to install.
  • FIGS. 53 to 55 are process diagrams showing the steps of manufacturing the coil unit according to Embodiment 13, and FIG. 56 is a completed view thereof.
  • the coil unit according to the present embodiment shown in FIG. 56 is different from the coil unit according to the embodiment 12 (FIG. 52) in that two coil windings of two turns are provided. That is, the coil unit according to the present embodiment is a switch unit.
  • each of the electric wires 21C and 21D is a flat wire that is a substantially U-shaped conductor plate in a side view, and has a terminal portion 72.
  • the wires 21A and 21B are for forming the primary winding of the switching transformer, and the wires 21C and 21D are for forming the secondary winding.
  • FIG. 54 shows a part constituting a primary winding
  • FIG. 55 shows a part constituting a secondary winding.
  • the four electric wires 21A to 21D are embedded with the insulator 22.
  • the same steps as in Fig. 51 were performed.
  • the core 24 is attached.
  • the two plate-shaped connecting members 25 are connected to the terminal portions 72 by welding or the like, thereby completing a coil unit having two twice-wound windings.
  • the same advantages as those in the embodiment 12 can be obtained.
  • the coil unit has a plurality of electric wires each having a first end and a second end, and the first ends of the plurality of electric wires are aligned with each other.
  • the direction of the second end is at least partly aligned with the first end, at least the first and second ends of each of the plurality of electric wires are exposed, and the plurality of electric wires are spaced from each other.
  • a magnetic core in which the insulator is inserted into a through hole formed selectively in the insulator to hold the plurality of electric wires.
  • the coil unit having the above-described configuration since a plurality of electric wires are embedded in the insulator so as to keep an interval from each other, an easy-to-handle component (referred to as a wiring portion) is formed in which the plurality of electric wires are integrated with each other while maintaining insulation. I do. Then, a structure in which a plurality of electric wires penetrate the core is completed by inserting an insulator constituting the wiring portion into the through hole of the magnetic core.
  • the coil unit having the above configuration can be easily assembled without requiring expensive equipment. Also, the first ends of the plurality of electric wires are aligned, and the direction of the second end of at least a part of the plurality of electric wires is also aligned with the first end.
  • a winding of one or more turns can be easily formed. Furthermore, when the second end that is aligned with the first end is two or more, various specifications with different inductances or number of windings can be easily realized by changing the connection method using the connection member. be able to. Also, since a plurality of electric wires are embedded in the insulator, vibration resistance is high and reliability is improved.
  • the insulator is formed by integrally molding an insulating material.
  • wiring part in which a plurality of electric wires are integrated with each other while maintaining insulation.
  • at least a part of the plurality of electric wires is all of the plurality of electric wires.
  • At least a part of the plurality of electric wires has a substantially U shape.
  • the plurality of electric wires may include a substantially linearly extending electric wire.
  • the first end of the substantially U-shaped electric wire and the second end of the substantially linearly extending electric wire are connected to an external circuit such as a circuit board, so that they are opposite to each other.
  • an external circuit such as a circuit board
  • the insulator embeds a pair of legs of a substantially U-shaped electric wire.
  • holding strength the strength of holding the plurality of electric wires by the insulator.
  • the insulator embeds the plurality of wires so that only the first and second ends of each of the plurality of wires are exposed.
  • the holding strength is further increased.
  • the plurality of electric wires may be embedded in the insulator so that a joint portion between a pair of legs of the substantially U-shaped electric wire is selectively exposed.
  • one leg of the pair of legs is inserted into the through hole of the core.
  • the wiring portion can be easily inserted into the core.
  • the core may be divided into a plurality along the one leg.
  • coil units of various specifications having different inductances simply by preparing a common core for coil units of various specifications and changing the number of cores used. That is, coil units of various specifications can be formed simply and inexpensively.
  • the core may be divided into a plurality of parts, and both of the pair of legs may be inserted into the divided core.
  • the core may be further divided into two or more along each of the pair of legs.
  • the plurality of electric wires are a plurality of conductor plates laminated with an interval therebetween, and the substantially U-shaped electric wire is a conductor plate having a substantially U-shaped contour in plan view.
  • the plurality of electric wires are a plurality of conductor plates laminated with an interval therebetween, and the substantially U-shaped electric wire is a conductor plate bent in a substantially U-shape in side view. .
  • Each of the plurality of electric wires is directly connected to a main surface at the first and second ends. It is desirable to have a plate-shaped terminal portion that is bent and protrudes from the main surface so as to stand upright. With this configuration, the plate-shaped terminal portions are parallel to each other, so that the first end and the second end, which are aligned in the same direction, can be easily connected by the connecting member to form the winding.
  • Each of the plurality of electric wires and the insulator may be formed of a flexible material.
  • the insulator has a retaining portion for preventing the insulator from coming off the core.
  • the core can be prevented from falling off from the wiring portion, and the vibration resistance of the coil unit can be improved.
  • the coil unit further includes at least one other structure configured identically to the structure having the plurality of electric wires and the insulator, wherein the through-hole is formed in the core.
  • the insulator which is divided into a plurality of rows arranged side by side and belongs to each of the structure and the at least one other structure, may be inserted into the divided through holes.
  • a coil unit having a plurality of wiring sections is realized, and since a plurality of wiring sections are inserted into a common core, there is no possibility that the plurality of cores may collide with each other due to vibration and may be damaged. A more excellent coil unit is realized. Further, since a common core is used, a core into which a plurality of wiring portions are inserted can be manufactured at a time.
  • the coil unit may be configured such that the orientation of the plurality of wires is uniform among the first and second ends of the plurality of wires so that the plurality of wires form N (N ⁇ l) windings.
  • a conductive connecting member for electrically connecting the connecting members.
  • the N may be 1.
  • a coil unit having one winding for example, a coil unit as a choke coil is realized.
  • N may be 2 or more.
  • a coil unit having two or more windings for example, a coil unit as a transformer is realized.
  • the plurality of electric wires may include an electric wire in which a diode is inserted in series.
  • the coil unit since the coil unit includes the reset circuit, the coil unit can be applied to the converter without separately providing a reset circuit.
  • the composite coil unit is configured to electrically connect the coil unit, at least one other coil unit configured identically to the coil unit, and the coil unit and the at least one other coil unit in parallel. And a conductive connector that performs the following.
  • the coil unit and the composite coil unit according to the present invention facilitate the manufacturing process, reduce the manufacturing cost, increase the vibration resistance, and increase the reliability, and are industrially useful.

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  • Engineering & Computer Science (AREA)
  • Power Engineering (AREA)
  • Coils Or Transformers For Communication (AREA)

Abstract

L'invention concerne une bobine d'induction et une bobine d'induction composite, dont le processus de production peut être simplifier pour réduire les coûts de production et qui résistent aux vibrations et sont très fiables. Dans cette bobine d'induction, des fils électriques (21) sensiblement en forme de U sont incorporés dans un corps isolant (22) de manière à être séparés les uns des autres et qu'une section terminale de chaque fil soit exposée comme section terminale (21a). Une section de branche du corps isolant (22) se présentant sensiblement en U est introduite dans un noyau (24) de corps magnétique. Des fils de bobinage peuvent être formés par connexion des sections terminales (21a) avec des éléments de connexion.
PCT/JP2003/015930 2002-12-13 2003-12-12 Bobine d'induction et bobine d'induction composite Ceased WO2004055840A1 (fr)

Priority Applications (1)

Application Number Priority Date Filing Date Title
AU2003289050A AU2003289050A1 (en) 2002-12-13 2003-12-12 Coil unit and compound coil unit

Applications Claiming Priority (4)

Application Number Priority Date Filing Date Title
JP2002362829A JP2004193506A (ja) 2002-12-13 2002-12-13 スイッチングトランス
JP2002-362829 2002-12-13
JP2002-365491 2002-12-17
JP2002365491A JP2004200309A (ja) 2002-12-17 2002-12-17 チョークコイルユニット

Publications (1)

Publication Number Publication Date
WO2004055840A1 true WO2004055840A1 (fr) 2004-07-01

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WO (1) WO2004055840A1 (fr)

Cited By (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2006015589A1 (fr) * 2004-08-12 2006-02-16 Epcos Ag Composant inductif pour courants eleves et procede de production de ce composant
US7124977B2 (en) 2003-10-15 2006-10-24 Actown Electrocoil, Inc. Magnetic core winding apparatus
US7990248B2 (en) 2005-02-11 2011-08-02 Epcos Ag Insulation alement and toroidal core throttle
EP2858203A1 (fr) * 2013-10-01 2015-04-08 ABB Technology AG Dispositif d'alimentation en énergie pour des unités de fonctionnement électroniques protégées contre les explosions
CN115621010A (zh) * 2022-10-31 2023-01-17 森根科技（苏州）有限公司 一种大功率电感

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JPS58212110A (ja) * 1982-06-03 1983-12-09 Mitsubishi Electric Corp 電磁誘導機器
JPH06302437A (ja) * 1993-04-13 1994-10-28 Mitsubishi Electric Corp 電力用コイル部品
JPH10208944A (ja) * 1996-11-21 1998-08-07 Tokin Corp インダクタ
JP2002165453A (ja) * 2000-11-27 2002-06-07 Denso Corp 二バッテリ搭載型車両用降圧型ｄｃ−ｄｃコンバータ装置
JP2002299124A (ja) * 2001-03-30 2002-10-11 Nippon Chemicon Corp インダクタンス素子

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Publication number Priority date Publication date Assignee Title
JPS58212110A (ja) * 1982-06-03 1983-12-09 Mitsubishi Electric Corp 電磁誘導機器
JPH06302437A (ja) * 1993-04-13 1994-10-28 Mitsubishi Electric Corp 電力用コイル部品
JPH10208944A (ja) * 1996-11-21 1998-08-07 Tokin Corp インダクタ
JP2002165453A (ja) * 2000-11-27 2002-06-07 Denso Corp 二バッテリ搭載型車両用降圧型ｄｃ−ｄｃコンバータ装置
JP2002299124A (ja) * 2001-03-30 2002-10-11 Nippon Chemicon Corp インダクタンス素子

Cited By (9)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US7124977B2 (en) 2003-10-15 2006-10-24 Actown Electrocoil, Inc. Magnetic core winding apparatus
US7154368B2 (en) 2003-10-15 2006-12-26 Actown Electricoil, Inc. Magnetic core winding method, apparatus, and product produced therefrom
WO2006015589A1 (fr) * 2004-08-12 2006-02-16 Epcos Ag Composant inductif pour courants eleves et procede de production de ce composant
US8063728B2 (en) 2004-08-12 2011-11-22 Epcos Ag Inductive component for high currents and method for the production thereof
US7990248B2 (en) 2005-02-11 2011-08-02 Epcos Ag Insulation alement and toroidal core throttle
EP2858203A1 (fr) * 2013-10-01 2015-04-08 ABB Technology AG Dispositif d'alimentation en énergie pour des unités de fonctionnement électroniques protégées contre les explosions
CN104518523A (zh) * 2013-10-01 2015-04-15 Abb技术股份公司 用于防爆的电子功能单元的能量供给装置
CN104518523B (zh) * 2013-10-01 2018-08-17 Abb瑞士股份有限公司 用于防爆的电子功能单元的能量供给装置
CN115621010A (zh) * 2022-10-31 2023-01-17 森根科技（苏州）有限公司 一种大功率电感

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